US10399323B2 - Smoke and soot removal systems for additive manufacturing - Google Patents

Smoke and soot removal systems for additive manufacturing Download PDF

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Publication number
US10399323B2
US10399323B2 US15/096,340 US201615096340A US10399323B2 US 10399323 B2 US10399323 B2 US 10399323B2 US 201615096340 A US201615096340 A US 201615096340A US 10399323 B2 US10399323 B2 US 10399323B2
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Prior art keywords
manifold
uptake
additive manufacturing
manufacturing system
inlet
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US15/096,340
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US20170291358A1 (en
Inventor
Matthew Donovan
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Collins Engine Nozzles Inc
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Delavan Inc
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Publication date
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Priority to US15/096,340 priority Critical patent/US10399323B2/en
Assigned to DELAVAN INC reassignment DELAVAN INC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DONOVAN, MATTHEW
Priority to EP17166216.6A priority patent/EP3231583B1/de
Publication of US20170291358A1 publication Critical patent/US20170291358A1/en
Priority to US16/557,749 priority patent/US11192353B2/en
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Publication of US10399323B2 publication Critical patent/US10399323B2/en
Assigned to Collins Engine Nozzles, Inc. reassignment Collins Engine Nozzles, Inc. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: DELAVAN INC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B15/00—Preventing escape of dirt or fumes from the area where they are produced; Collecting or removing dirt or fumes from that area
    • B08B15/002—Preventing escape of dirt or fumes from the area where they are produced; Collecting or removing dirt or fumes from that area using a central suction system, e.g. for collecting exhaust gases in workshops
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B15/00—Preventing escape of dirt or fumes from the area where they are produced; Collecting or removing dirt or fumes from that area
    • B08B15/007—Fume suction nozzles arranged on a closed or semi-closed surface, e.g. on a circular, ring-shaped or rectangular surface adjacent the area where fumes are produced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B08—CLEANING
    • B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
    • B08B15/00—Preventing escape of dirt or fumes from the area where they are produced; Collecting or removing dirt or fumes from that area
    • B08B15/04—Preventing escape of dirt or fumes from the area where they are produced; Collecting or removing dirt or fumes from that area from a small area, e.g. a tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/70—Recycling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/60—Planarisation devices; Compression devices
    • B22F12/63—Rollers
    • B22F3/1055—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/35—Cleaning
    • B22F2003/1059—
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency
    • Y02P10/295—

Definitions

  • the present disclosure relates to additive manufacturing, more specifically to smoke and soot removal systems for additive manufacturing.
  • Certain laser based powder bed fusion additive manufacturing systems remove smoke and soot during the manufacturing process. Smoke is generated when the laser welds the powder to the previous layer. Smoke generated can cause build quality issues including failures. Traditional systems only remove smoke by using an intake pipe that is disposed several inches away from the source of smoke generation (e.g. the build area).
  • An intake manifold for an additive manufacturing system includes a body defining a flow channel therein.
  • the body includes an inlet end defining an inlet configured to intake gas and/or particles from a build area of the additive manufacturing system, and an outlet end defining an outlet that is fluidly connected to the inlet through the flow channel.
  • the outlet is configured to be in fluid communication with an uptake manifold of the additive manufacturing system.
  • the intake manifold also includes at least one mount extending from the outlet end of the body that is configured to rotatably mount the body to the uptake manifold.
  • the at least one mount can include two mounts disposed at opposite lateral sides of the body.
  • the two mounts can include a C-shape configured to mount to the uptake manifold.
  • the intake manifold can include pair of bearings configured to be attached to the uptake manifold and to fit within the C-shape mounts to allow the body to rotate around the uptake manifold on the bearings.
  • the body can include a curved shape on at least a rear face thereof for indexing against a roller of the additive manufacturing system such that the roller can push against the rear face of the body to rotate the body about the uptake manifold.
  • the intake manifold can include one or more border inlet arms extending from the inlet end and configured to border at least a portion of the build area to allow gas and/or particulate intake from the build area.
  • the inlet can include a plurality of openings disposed on the inlet end and the border inlet arms.
  • the intake manifold can include at least one of a polymer, ceramic, or a metal or any other suitable material.
  • an additive manufacturing system can include an uptake manifold and an intake manifold as described above rotatably connected the uptake manifold.
  • FIG. 1A is a perspective view of an embodiment of an intake manifold in accordance with this disclosure
  • FIG. 1B is a perspective cross-sectional view of the embodiment of FIG. 1A ;
  • FIG. 2 is a partial perspective view of an embodiment of a system in accordance with this disclosure, showing the intake manifold of FIG. 1A rotatably disposed on an uptake manifold;
  • FIG. 3 is a partial perspective view of an embodiment of a system in accordance with this disclosure, showing a pair of bearings disposed on an uptake manifold.
  • FIG. 1A an illustrative view of an embodiment of an intake manifold in accordance with the disclosure is shown in FIG. 1A and is designated generally by reference character 100 .
  • FIGS. 1B-3 Other embodiments and/or aspects of this disclosure are shown in FIGS. 1B-3 .
  • the systems and methods described herein can be used to improve smoke and soot removal and improve build quality of an additive manufacturing system.
  • an intake manifold 100 for an additive manufacturing system includes a body 101 defining a flow channel 101 a therein.
  • the body 101 includes an inlet end 103 defining an inlet 103 a configured to intake gas and/or particles from a build area (e.g., build area 201 as shown in FIG. 2 ) of the additive manufacturing system.
  • the body 101 also defines an outlet end 105 defining an outlet 105 a fluidly connected to the inlet 103 a through the flow channel 101 a.
  • the intake manifold 100 can include at least one of a polymer, ceramic, or a metal. Any other suitable material for the intake manifold 100 is contemplated herein.
  • the outlet 105 a is configured to be in fluid communication with an uptake manifold 203 of the additive manufacturing system 100 such that the uptake manifold can pull gas and/or particulate through the inlet 103 a , through the flow channel 101 a , and out through the outlet 105 a . While not shown, it is contemplated that a seal or other flexible channel can be disposed between the uptake manifold 203 and the outlet end 105 , and/or the outlet end 105 can conform to the shape of the uptake manifold 203 such that leakage between the uptake manifold 203 and the outlet end 105 is prevented.
  • the intake manifold 100 also includes one or more mounts 107 extending from the outlet end 105 of the body 101 .
  • the mounts 107 are configured to rotatably mount the body 101 to the uptake manifold 203 .
  • the one or more mounts 107 can include two mounts 107 disposed at opposite lateral sides of the body 101 . Also as shown, the two mounts 107 can include a C-shape configured to mount to the uptake manifold 203 (e.g., which has a pipe shape). Any other suitable shape for the one or more mounts 107 is contemplated herein.
  • the intake manifold 100 can include one or more border inlet arms 111 extending from the inlet end 103 and configured to border at least a portion of the build area 201 to allow gas and/or particulate intake from the build area 201 around at least a portion of the perimeter of the build area 201 .
  • at least a portion of the arms 111 can be hollow. It is contemplated that the border inlet arms 111 can extend down an entire length of the build area 201 and/or completely surround the perimeter of the build area 201 (e.g., by forming a square frame).
  • the inlet 103 a can include a plurality of openings 103 b disposed on the inlet end 103 and/or the border inlet arms 111 .
  • the openings 103 b can be of a suitable size to allow soot and smoke to be drawn through without allowing powder from the build area 201 to be pulled through.
  • the openings 103 b can open upwardly such that gas and or particulate is pulled in from just above the build area 201 (e.g., such that a longitudinal direction of the channel through the wall defining the inlet 103 a and/or the arms 111 points at least partially upward). Any other suitable size and/or shape of the openings 103 b is contemplated herein.
  • the intake manifold 100 and/or the system 200 can include one or more bearings 109 (e.g., a pair as shown) that are configured to be attached to the uptake manifold 203 and to fit within the mounts 107 to allow the body 101 to rotate around the uptake manifold 203 on the bearings 109 .
  • the bearings 109 can be first placed on the uptake manifold 203 , and then the mounts 107 can be clips to the bearings 109 .
  • the bearings 109 can include any suitable type of bearing (e.g., nylon or other low friction material bushings, a ball bearing). It is contemplated that the mounts 107 can rotatably mount to the uptake manifold 203 in any other suitable manner.
  • the body 101 can include a curved shape on at least a rear face 101 b thereof for indexing against a roller 205 of the additive manufacturing system 200 such that the roller 205 can push against the rear face 101 b of the body 101 to rotate the body 101 about the uptake manifold 203 .
  • the roller 205 can translate across the system 200 to roll powder onto the build area 201 .
  • the roller 205 can contact the rear face 101 b and lifts the intake manifold 100 out of the way, allowing the roller 205 to roll over the build area 201 .
  • the arms 111 can rest on top of the roller 205 as the roller 205 traverses the build area 201 .
  • the roller 205 can be configured to hold up an intake manifold 100 that does not have arms 111 (e.g., with extensions extending backward from the roller 205 to hold the intake manifold up).
  • the intake manifold 100 can then fall back downward. It is contemplated that the intake manifold 100 can be electrically and/or mechanically (e.g., via a suitable motor) operated by a controller (e.g., a CPU) of the system 200 to raise up and lower without the assistance of the roller 205 .
  • a controller e.g., a CPU
  • Embodiments as described above can dramatically improve smoke removal of the certain additive manufacturing systems (e.g., the ProX300 TM system) thereby improving part build reliability and part quality.
  • certain embodiments allow smoke to be remove from two, three, and/or four sides of the build area 201 , which can significantly improving inerting atmosphere and build quality, as well as preventing particulate clouds

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Powder Metallurgy (AREA)
US15/096,340 2016-04-12 2016-04-12 Smoke and soot removal systems for additive manufacturing Active 2037-07-05 US10399323B2 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US15/096,340 US10399323B2 (en) 2016-04-12 2016-04-12 Smoke and soot removal systems for additive manufacturing
EP17166216.6A EP3231583B1 (de) 2016-04-12 2017-04-12 Rauch- und russentfernungssysteme zur generativen fertigung
US16/557,749 US11192353B2 (en) 2016-04-12 2019-08-30 Smoke and soot removal systems for additive manufacturing

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15/096,340 US10399323B2 (en) 2016-04-12 2016-04-12 Smoke and soot removal systems for additive manufacturing

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US16/557,749 Division US11192353B2 (en) 2016-04-12 2019-08-30 Smoke and soot removal systems for additive manufacturing

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US20170291358A1 US20170291358A1 (en) 2017-10-12
US10399323B2 true US10399323B2 (en) 2019-09-03

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US16/557,749 Active 2036-05-30 US11192353B2 (en) 2016-04-12 2019-08-30 Smoke and soot removal systems for additive manufacturing

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US16/557,749 Active 2036-05-30 US11192353B2 (en) 2016-04-12 2019-08-30 Smoke and soot removal systems for additive manufacturing

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11759861B2 (en) 2021-04-16 2023-09-19 General Electric Company Additive manufacturing build units with process gas inertization systems
US11938539B2 (en) 2021-04-16 2024-03-26 General Electric Company Additive manufacturing build units with process gas inertization systems

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017125838A1 (de) 2017-11-06 2019-05-09 Trumpf Laser- Und Systemtechnik Gmbh Absaugung bei der generativen Fertigung
US11020763B2 (en) 2018-08-21 2021-06-01 General Electric Company Spacer flow guide for partitioning build chamber of an additive manufacturing system
US11203027B2 (en) 2018-08-21 2021-12-21 General Electric Company Lower gas flow injection system and method for additive manufacturing system

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US1908821A (en) * 1930-04-29 1933-05-16 Chase Companies Inc Branch-fitting for pipes
US4253224A (en) * 1978-12-18 1981-03-03 Brazeway, Inc. Fixtureless method of making tube joints
US4966397A (en) * 1989-09-01 1990-10-30 Mckinnon Robert M Flexible pipe saddle
EP0606538A1 (de) 1993-01-14 1994-07-20 BECKER VERFAHRENSTECHNIK, DIPL. ING. ERNST BECKER GmbH & CO KG Steinstaubabsaugung
US5336130A (en) * 1993-03-04 1994-08-09 Metal-Fab, Inc. Adjustable exhauster arm assembly
WO1997005421A1 (en) 1995-07-28 1997-02-13 Ozone Manufacturing Pty. Ltd. Centilevered adjustable hollow arm and joints therefor
US6056073A (en) * 1997-03-17 2000-05-02 S.M.F. International Element of a rotating drill pipe string
WO2002038033A2 (en) 2000-11-10 2002-05-16 Jlj Medical Devices International, Llc Smoke evacuation system
US20080169586A1 (en) * 2007-01-17 2008-07-17 Hull Charles W Imager Assembly and Method for Solid Imaging
US20150027993A1 (en) 2013-07-29 2015-01-29 Siemens Energy, Inc. Flux for laser welding
DE102014209161A1 (de) 2014-05-14 2015-11-19 Eos Gmbh Electro Optical Systems Steuereinheit, Vorrichtung und Verfahren zum Herstellen eines dreidimensionalen Objekts

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1908821A (en) * 1930-04-29 1933-05-16 Chase Companies Inc Branch-fitting for pipes
US4253224A (en) * 1978-12-18 1981-03-03 Brazeway, Inc. Fixtureless method of making tube joints
US4966397A (en) * 1989-09-01 1990-10-30 Mckinnon Robert M Flexible pipe saddle
EP0606538A1 (de) 1993-01-14 1994-07-20 BECKER VERFAHRENSTECHNIK, DIPL. ING. ERNST BECKER GmbH & CO KG Steinstaubabsaugung
US5336130A (en) * 1993-03-04 1994-08-09 Metal-Fab, Inc. Adjustable exhauster arm assembly
WO1997005421A1 (en) 1995-07-28 1997-02-13 Ozone Manufacturing Pty. Ltd. Centilevered adjustable hollow arm and joints therefor
US6056073A (en) * 1997-03-17 2000-05-02 S.M.F. International Element of a rotating drill pipe string
US6663610B1 (en) * 1998-04-17 2003-12-16 Leonard S. Schultz, M.D. Smoke evacuation system
WO2002038033A2 (en) 2000-11-10 2002-05-16 Jlj Medical Devices International, Llc Smoke evacuation system
US20080169586A1 (en) * 2007-01-17 2008-07-17 Hull Charles W Imager Assembly and Method for Solid Imaging
US20150027993A1 (en) 2013-07-29 2015-01-29 Siemens Energy, Inc. Flux for laser welding
DE102014209161A1 (de) 2014-05-14 2015-11-19 Eos Gmbh Electro Optical Systems Steuereinheit, Vorrichtung und Verfahren zum Herstellen eines dreidimensionalen Objekts
US20170072468A1 (en) * 2014-05-14 2017-03-16 Eos Gmbh Electro Optical Systems Control Unit, Device and Method for the Production of a Three-Dimensional Object

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Extended European Search Report prepared by Examiner Benoit Gasner, of the European Patent Office, dated Sep. 5, 2017, issued in corresponding European Patent Application No. 17166216.6.

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11759861B2 (en) 2021-04-16 2023-09-19 General Electric Company Additive manufacturing build units with process gas inertization systems
US11938539B2 (en) 2021-04-16 2024-03-26 General Electric Company Additive manufacturing build units with process gas inertization systems

Also Published As

Publication number Publication date
US20190381781A1 (en) 2019-12-19
US20170291358A1 (en) 2017-10-12
EP3231583B1 (de) 2020-04-22
US11192353B2 (en) 2021-12-07
EP3231583A1 (de) 2017-10-18

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